Thin film transistor, method of producing the same, eletctrooptic apparatus, and sensor

ABSTRACT

A thin film transistor includes: a substrate; and, on the substrate, an oxide semiconductor film which serves as an active layer and contains In, Ga, and Zn, a gate electrode, a gate insulating film, a source electrode, and a drain electrode, wherein, when a molar ratio of In, Ga, and Zn in the oxide semiconductor film is expressed as In:Ga:Zn=(2.0−x):x:y, wherein 0.0&lt;x&lt;2.0 and 0.0&lt;y, the distribution of y in the thickness direction of the oxide semiconductor film is such that the oxide semiconductor film has a region at which a value of y is larger than that at a surface of the oxide semiconductor film at a side closer to the substrate and that at a surface of the oxide semiconductor film at a side farther from the substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This Application claims priority under 35 USC 119 from Japanese PatentApplication No. 2009-140426, filed on Jun. 11, 2009, the disclosure ofwhich is incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a thin film transistor, a method ofproducing the same, an electrooptic apparatus, and a sensor.

2. Description of the Related Art

Since the report made by the group led by Professor Hideo Hosono(Frontier Research Center & Materials and Structures Laboratory of theTokyo Institute of Technology) and other researchers, there has been anincrease in studies of the application of In—Ga—Zn—O oxide materials(also which may be referred to as “IGZO” or “IGZO materials”hereinafter) to active layers of thin film transistors (TFTs) (see, forexample, Science, 300 (2003) 1269, Nature, 432 (2004) 488).

The IGZO materials exhibit higher carrier mobility than that ofamorphous silicon (a-Si). In addition, IGZO materials can be formed intofilms on resin substrates at low temperatures. For these reasons, it isexpected that IGZO materials will be applied to, for example, drivingelements of flexible displays or the like in the future.

As an example of a TFT prepared using an IGZO material, a TFT isdisclosed in which an active layer, as well as a high-resistance layerthat is arranged between the active layer and a gate insulating film,are formed from IGZO material, thereby attaining excellent TFTproperties (see, for example, Japanese Patent Application Laid-Open(JP-A) No. 2007-73701).

SUMMARY OF THE INVENTION

In the TFTs prepared using IGZO materials, including the TFT disclosedin JP-A No. 2007-73701, on-state currents may be low, and the propertiesof the transistors may shift (deviate) from ideal properties astransistors.

The present invention has been made in view of the above circumstancesand provides a thin film transistor, a method of producing the same, anelectrooptic apparatus, and a sensor.

According to a first aspect of the invention, there is provided a thinfilm transistor including:

a substrate; and, on the substrate,

an oxide semiconductor film which serves as an active layer and containsIn, Ga, and Zn, a gate electrode, a gate insulating film, a sourceelectrode, and a drain electrode,

wherein, when a molar ratio of In, Ga, and Zn in the oxide semiconductorfilm is expressed as In:Ga:Zn=(2.0−x):x:y wherein the inequalities0.0<x<2.0 and 0.0<y are satisfied, the distribution of y in thethickness direction of the oxide semiconductor film has a region atwhich a value of y is larger than that at a surface of the oxidesemiconductor film at a side closer to the substrate and that at asurface of the oxide semiconductor film at a side farther from thesubstrate.

According to a second aspect of the invention, there is provided amethod of producing the thin film transistor according to the firstaspect of invention, the method including: forming at least a part ofthe oxide semiconductor film, including a region at which the value of yis at least 90% of the absolute maximum value thereof over an entirethickness of the oxide semiconductor film, by a series of consecutivefilm-forming processes during which the part of the oxide semiconductorfilm is not exposed to the atmosphere.

According to a third aspect of the invention, there is provided anelectrooptic apparatus including the thin film transistor of the firstaspect of invention.

According to a fourth aspect of the invention, there is provided asensor comprising the thin film transistor of the first aspect ofinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a conceptual diagram showing an example of y distribution inthe film thickness direction of an IGZO film in the invention;

FIG. 2 is a conceptual diagram showing an example of y distribution inthe film thickness direction of an IGZO film in the invention;

FIG. 3 is a flow chart showing an example of a method of producing athin film transistor (TFT) according to the invention;

FIG. 4 is a flow chart showing an example of a method of producing athin film transistor (TFT) according to the invention;

FIG. 5 is a schematic diagram showing an example of a top-gate thin filmtransistor;

FIG. 6 is a schematic diagram showing a liquid crystal display devicewhich is an example of an electrooptic apparatus of the invention;

FIG. 7 shows a conceptual sectional view of an X-ray sensor which is anexample of a sensor of the invention;

FIG. 8 shows the results of measurements of transistor properties (Vg-Idcharacteristics) measured in the Examples of the invention;

FIG. 9 shows the results of measurements of transistor properties (Vg-Idcharacteristics) measured in the Examples of the invention;

FIG. 10 is a diagram showing a comparison in carrier mobility ofExamples 1, 2, and 3 and Comparative Example 3; and

FIG. 11 is a diagram showing a comparison in on/off ratios (i.e., ratiosof on-state current/off-state current) of Examples 1, 2, and 3 andComparative Example 3.

DETAILED DESCRIPTION OF THE INVENTION

Thin Film Transistor and Method of Producing the Same

A thin film transistor of the invention includes a substrate, and anoxide semiconductor film, a gate electrode, a gate insulating film, asource electrode, and a drain electrode, which are provided on thesubstrate, the oxide semiconductor film including In, Ga, and Zn andserving as an active layer. In the thin film transistor, when the molarratio of In, Ga, and Zn (i.e., In:Ga:Zn ratio) of the oxidesemiconductor film is expressed by an expression, In:Ga:Zn=(2.0−x):x:y(wherein 0.0<x<2.0, and 0.0<y are satisfied), the distribution of y(which may be referred to as “y distribution” hereinafter) in thethickness direction of the oxide semiconductor film has a region, in thethickness direction of the oxide semiconductor film, at which the valueof y (which may be referred to as “y value” hereinafter) is larger thanthe value of y at a film surface at a side closer to the substrate andthe value of y at a film surface at a side farther from the substrate.

In recent years, studies have been conducted on application of an oxidesemiconductor film containing In, Ga, and Zn (which may be referred toas “IGZO film” hereinafter) to an active layer of a thin film transistor(which may be referred to as “TFT” hereinafter). In general, IGZO filmsthat have been used so far have a molar ratio of the respective metalelements (i.e., In:Ga:Zn ratio) in the IGZO film of 1.0:1.0:1.0 or about1.0:1.0:1.0.

However, when the IGZO film having such a molar ratio is used as anactive layer of a TFT, the on-state current may be insufficient.

In this regard, when an IGZO film, in which the molar ratio of Zn isincreased to have an In:Ga:Zn ratio of from 1.0:1.0:2.0 to 1.0:1.0:5.0,is used as the active layer of a TFT, the on-state current obtainedtends to be increased. However, the increased Zn ratio results in adecrease of the resistance of the active layer, and thus significantlychanges TFT properties (specifically, shifting the Vg-Id characteristiccurve of the TFT towards the negative Vg side (hereinafter referred toas “characteristics shift” in some cases); this shift is observed in thecase of, for example, the characteristics curve for “In:Ga:Zn=1:1:2shown in FIG. 8). When the shift is large, negative gate bias has to beapplied to the TFT in order to turn off the TFT.

In this regard, when a TFT is made to have the configuration of theinvention so as to have a Zn-rich region (region having a high Zn molarratio) in an active layer, the characteristics shift can be preventedwhile a high on-state current (i.e., high carrier mobility) is attained.

Furthermore, according to the invention, since the characteristics shiftcan be reduced, the gate bias applied for causing the TFT to get intothe off-state can be reduced. In other words, a normally-off TFT caneasily be obtained while a high on-state current (i.e., high carriermobility) is attained.

In addition, according to the invention, since the gate bias is reduced,electrical consumption for driving a TFT can be reduced.

In the invention, a state where a high on-state current is attained andthe characteristics shift is reduced, and a state where, in addition tothese conditions, a low off-state current is attained may be simplyreferred to “having excellent transistor properties”.

In the following, an example of the IGZO film of the invention isdescribed by referring to FIGS. 1 and 2. However, the invention is notlimited to this example.

Each of FIGS. 1 and 2 is a conceptual diagram showing an example of ydistribution in the film thickness direction of an IGZO film of theinvention.

In FIGS. 1 and 2, the horizontal axis indicates percentagewise a filmthickness of an IGZO film, in which a film thickness of “0%” indicates asurface of the IGZO film at a side closer to a substrate, and a filmthickness of “100%” indicates a surface of the IGZO film at a sidefarther from the substrate.

In FIGS. 1 and 2, the vertical axis indicates the y value when the molarratio of In, Ga, and Zn (i.e., In:Ga:Zn molar ratio) is expressed by theexpression, In:Ga:Zn=(2.0−x):x:y (provided that 0.0<x<2.0, and 0.0<y aresatisfied).

In FIGS. 1 and 2, distribution curves “a” to “e” each represent examplesof y distribution of the invention, and each shows that a region atwhich the y value is larger than that at the film surface at a sidecloser to a substrate (i.e., the position indicated by the thickness of0% in FIGS. 1 and 2) and the film surface at a side farther from thesubstrate (i.e., the position indicated by the thickness of 100% inFIGS. 1 and 2). In other words, the IGZO film of the invention includes,at the interior of the film, a region at which the y value is largerthan the y values at both surfaces (i.e., the film surface at a sidecloser to the substrate and the film surface at a side farther from thesubstrate) of the IGZO film.

The region at interior of the film at which the y value is relativelyhigh (i.e., Zn-rich region) contributes to increase in on-state current.

Meanwhile, regions which are present at both surfaces of the film and atwhich the y values are relatively low contribute to reducingcharacteristics shift.

The y distribution in the thickness direction in the invention may bemeasured by element analysis in the depth direction by X-rayphotoelectron spectroscopy (XPS) or secondary ion mass spectrometry(SIMS), or by cross-sectional TEM-EDX, for example. For example, the ydistribution in a cross-sectional sample which has been processed byfocused ion beam (FIB) is measured by energy dispersive X-rayspectroscopy (EDX) in combination with transmission electron microscopy(acceleration voltage: 200 kV to 300 kV). The line analysis may beperformed under the conditions of a beam diameter of 1 nm or less and aresolution of from 120 to 150 eV, whereby highly accurate elementdistribution in the thickness direction can be evaluated. For example,the evaluation may be performed using a transmission electron microscope(TEM) (trade name: HD-2700, manufactured by Hitachi Hi-TechnologiesCorporation) and an energy dispersive X-ray spectrometer (EDX) (tradename: GENESIS, manufactured by EDAX) under the following conditions;beam diameter: 0.4 nm, measurement time per 1 point: 1 second, and thenumber of measurement points incorporated: from 200 to 300 for a samplehaving a thickness of about 100 nm.

In the invention, the film surface at a side closer to the substratecorresponds to the surface of an IGZO film at a side closer to a gateinsulating film in a bottom-gate TFT, and corresponds to the surface ofan IGZO film at a side farther from a gate insulating film in a top-gateTFT.

The film surface at a side farther from the substrate corresponds to thesurface of an IGZO film at a side farther from a gate insulating film ina bottom-gate TFT, and corresponds to the surface of an IGZO film at aside closer to a gate insulating film in a top-gate TFT.

When a y value at the IGZO film surface at a side closer to a gateinsulating film is larger than the y value at an internal portion of theIGZO film, a channel is formed at the interface between the IGZO filmsurface and the gate insulating film. Accordingly, owing to deficiency,contaminants, and the like which are present at the interface (i.e.,contact surface between the gate insulating film and the IGZO film), theon-state current (carrier mobility) may be reduced, or transistorproperties may become unstable.

When the y value at the IGZO film surface at a side farther from a gateinsulating film is larger than the y value at an internal portion of theIGZO film, the off-state current may be increased, adequate on/off ratiomay not be attained, or transistor properties may be unstable.

The y distribution in the thickness direction may be a curveddistribution (e.g., distribution curve “a” shown in FIG. 1), a lineardistribution (e.g., distribution curve “b” or “d” shown in FIG. 1), or adistribution curve including a curved portion and a linear portion(e.g., distribution curve “c” shown in FIG. 1 or distribution curve “e”shown in FIG. 2).

In the following, embodiments of the y distribution, which are furtherpreferable from the viewpoint of more effectively exerting the effect ofthe invention, are described.

From the viewpoint of increasing an on-state current (carrier mobility),the absolute maximum y value over the y distribution is preferably 1.8or more (see, for example, distribution curves “a” to “e” shown in FIGS.1 and 2).

From the viewpoint of increasing an on-state current (carrier mobility),the absolute maximum y value is preferably 5.0 or less (see, forexample, distribution curves “b” to “e” shown in FIGS. 1 and 2).

Accordingly, from the viewpoint of increasing an on-state current(carrier mobility), the absolute maximum y value over the y distributionis more preferably from 1.8 to 5.0, further more preferably from 1.8 to4.0, even more preferably from 1.8 to 3.0, and particularly preferablyfrom 1.8 to 2.2.

It is preferable that at least a part of the IGZO film (more preferablythe entire IGZO film in the invention), which includes a region at whichthe y value is at least 90% of the absolute maximum y value, is formedby a series of consecutive film-forming processes, whereby contaminationor deficiency at interfaces of respective regions due to the atmospherecan be prevented, and superior transistor properties can be attained.Moreover, the number of processes to form the IGZO film can be reduced,whereby production cost can be reduced.

As an example of conventional TFTs, JP-A No. 2007-73701 discloses that aTFT having good properties is obtained by forming an active layer aswell as a high-resistance layer that is arranged between the activelayer and a gate insulating film using an IGZO. JP-A No. 2007-73701discloses that a suitable interface between the active layer and thehigh-resistance layer can be formed because the high-resistance layer inthe amorphous state is planar. However, since the active layer andhigh-resistance layer are formed as independent layers having differentshapes, and the high-resistance layer is formed after formation of asource electrode and a drain electrode subsequent to forming the activelayer, the interface between the active layer and the high-resistancelayer may easily be contaminated, or may have deficiency. Furthermore,since an interface of the active layer at a side opposite to theinterface between the active layer and gate insulating layer is nottreated, deficiency is likely to be generated and is one of the factorsthat affect the device properties. For these reasons, it has beendifficult to obtain sufficient transistor properties regardingachievement of stability and reliability, and regarding achievement ofboth favorable on property and favorable off property. Moreover,increase in production cost due to increase in number of processes hasbeen problematic.

In contrast to the disclosure of JP-A No. 2007-73701, an embodiment of“formation by a series of consecutive film-forming processes” used inthe invention prevents contamination at the interface caused by theatmosphere and prevents occurrence of deficiency at the interface,resulting in superior transistor properties. In addition, the number ofprocesses of forming the film can be reduced in the invention, wherebyproduction cost can be reduced.

In the invention, from the viewpoint of effectively attaining thebalance between the increase in on-state current and the suppression ofcharacteristics shift, a thickness of a region at which y value is atleast 90% of the absolute maximum y value of the oxide semiconductorfilm (t_(max)) is less than one-third of a total thickness of the oxidesemiconductor film, as shown by the distribution curve “e” in FIG. 2.

The center, in the thickness direction, of the region at which the yvalue is at least 90% of the absolute maximum y value over the ydistribution is preferably positioned at a side closer to the gateinsulating film (or closer to the substrate when the TFT is abottom-gate TFT) with respect to the center of the oxide semiconductorfilm in the thickness direction, whereby a channel can be formed in theregion having a large y value, and the on-state current can beadditionally increased.

For similar reasons, the region at which the y value is at least 90% ofthe absolute maximum y value over the y distribution is preferablyincluded in a region ranging from 1 nm to 30 nm, in the thicknessdirection of the oxide semiconductor film, from thegate-insulating-film-side surface of the oxide semiconductor film (or,if the TFT is a bottom-gate TFT, from a surface of the oxidesemiconductor film at a side closer to the substrate).

The IGZO film used in the invention is preferably amorphous.

Among IGZO films, an amorphous IGZO film can be formed at particularlylow temperatures (for example, at a substrate temperature of 200° C. orless), and can be easily formed on a flexible resin substrate such as aplastic substrate. Accordingly, an amorphous IGZO film can be moreeasily applied to production of a flexible display having a plasticsubstrate with a TFT thereon.

Furthermore, it is easy to form a uniform film over a large area usingthe amorphous IGZO film, and variations of device properties can bereduced because the amorphous IGZO film is free from grain boundaryunlike polycrystalline materials.

Whether the IGZO film is amorphous or not may be confirmed by X-raydiffraction. Specifically, when a distinct peak that indicates acrystalline structure is not found by X-ray diffraction, the IGZO filmis determined to be amorphous.

Hereinafter, a surface of the IGZO film at a side closer to thesubstrate may be referred to as surface A of the IGZO film, and asurface of the IGZO film at a side farther from the substrate may bereferred to as surface B of the IGZO film. From the viewpoints ofeffectively exerting the effect of the invention and facilitatingproduction, it is preferable that the IGZO film of the inventionincludes: a first region which includes the surface A of the IGZO filmand at which the y value is from 0.8 to 1.2; a second region whichincludes the surface B of the IGZO film and at which the y value is from0.8 to 1.2; and a third region which includes a region at which y takesthe absolute maximum value and at which the y value is 1.8 or more (forexample, distribution curves “c”, “d”, and “e”).

It is preferable that at least one of the change in y value from thefirst region to the third region and the change in y value from thethird region to the second region is continuous (for example,distribution curves “a” to “c” and “e”).

In the above, the thin film transistor of the invention is describedfocusing on the configuration of the IGZO film which serves as an activelayer. Known configurations may be applied, without particularlimitations, to configurations of other elements (such as a gateelectrode, a gate insulating film, a source electrode, and a drainelectrode).

The thin film transistor of the invention may have, as required, anadditional element such as a known inter-layer insulating film (whichmay be referred to as “passivation film” or “protective film”) or aknown pixel electrode.

The thin film transistor of the invention may be a bottom-gate TFT or atop-gate TFT. From the viewpoint of effectively exerting the effect ofthe invention, the thin film transistor is preferably a bottom-gate TFT.

Embodiments

In the following, specific embodiments of a thin film transistor of theinvention are described by referring to the production method thereof.However, the invention is not limited to these embodiments.

FIG. 3 and FIG. 4 are flow charts showing an example of a method ofproducing a thin film transistor (TFT) of the invention.

Substrate

First, a substrate 10 for forming a TFT is provided (see FIG. 3(A)).

The shape, structure, size and the like of the substrate 10 are notparticularly limited, and appropriately selected in accordance with theintended purpose or the like. The substrate 10 may have a single layerstructure, or may have a laminated structure (a multilayer structure).

The substrate 10 is not particularly limited, and examples thereofinclude inorganic substrates formed from zirconia-stabilized yttrium(YSZ) or glass; and resin substrates (which may be referred to as“plastic substrates” hereinafter) formed from a synthetic resin such aspolyester (e.g., polyethylene terephthalate (PET), polybutyleneterephthalate, or polyethylene naphthalate (PEN)), polystyrene,polycarbonate, polyether sulfone, polyarylate, allyl diglycol carbonate,polyimide, polycycloolefin, norbornene resin, or poly(chlorotrifluoroethylene).

Of these, resin substrates are preferable from the viewpoints of beinglightweight and having flexibility.

When the substrate 10 is a resin substrate, the resin substratepreferably has excellent heat resistance, excellent dimensionalstability, excellent solvent resistance, excellent electrical insulationproperty, excellent workability, low gas permeability, low hygroscopicproperty, or the like.

In general, resin substrates have poor heat resistance. Therefore, whenan electronic device is formed on a resin substrate, the processtemperature in the production of the electronic device is preferably200° C. or lower, more preferably 150° C. or lower, and particularlypreferably 100° C. or lower.

In this regard, since an IGZO film, which can be formed (for example, bysputtering) at low temperatures, is used as a semiconductor layer in theelectronic device of the invention, the process temperature in theproduction of the electronic device can be set to 200° C. or lower.

Accordingly, a TFT, for example, can be formed on a resin substrate toserve as an electronic device of the invention, and a flexible displaycan be prepared using the thus-obtained TFT substrate.

The resin substrate may be provided with, for example, at least one of abarrier layer preventing permeation of moisture or oxygen, an undercoatlayer for improving flatness of the resin substrate or adhesion to alower electrode, or another layer.

In the invention, the thickness of the substrate is preferably from 50μm to 500 μm.

When the thickness of the substrate is 50 μm or more, the flatness ofthe substrate is more improved.

When the thickness of the substrate is 500 μm or less, flexibility ofthe substrate is more improved, and the use of the substrate as asubstrate for a flexible display is facilitated.

Gate Electrode

A gate electrode 12 is formed on the substrate 10 (FIG. 3 (B)).

The material of the gate electrode 12 may be a material having electricconductivity and thermal resistance (500° C. or higher). Examples ofmaterials that can be used for forming an electrically conductive filmof the gate electrode 12 include metals such as Al, Mo, Cr, Ta, Ti, Au,and Ag; alloys such as Al—Nd and APC (trade name, manufactured by FuruyaMetal Co., Ltd.; Ag alloy); and metal oxide electrically conductivefilms such as a conductive film of tin oxide, zinc oxide, indium oxide,indium tin oxide (ITO), or indium zinc oxide (IZO).

The structure of the gate electrode 12 may be a single layer structureconsisting of an electrically conductive film, or may be a laminatedstructure (multi-layer structure) of two or more electrically conductivefilms; the electrically conductive film or the electrically conductivefilms may be selected from those described above.

The gate electrode 12 is formed on the substrate 10 by, for instance, amethod appropriately selected in consideration of the suitability to thematerial that is used to form the gate electrode. Examples thereofinclude wet methods such as a printing method and a coating method;physical methods such as a vacuum deposition method, a sputteringmethod, and an ion plating method; and chemical methods such as CVD(chemical vapor deposition) and a plasma CVD method. The thickness ofthe gate electrode 12 is preferably from 10 nm to 1000 nm (morepreferably from 50 nm to 200 nm).

For example, a Mo film, an Al film, an Al—Mo film, or a multilayer filmcomposed of a combination thereof is formed by, for example, sputtering.

After the film formation, patterning by photolithography and etching isperformed to give a predetermined shape. In this process, it ispreferred that the patterning of the gate electrode 12 is performedsimultaneously with the patterning of gate wires (not shown).

Gate Insulating Film

After forming the gate electrode 12 on the substrate 10, a gateinsulating film 14 is formed (FIG. 3 (C)).

The gate insulating film 14 is a film having insulating property andthermal resistance (500° C. or higher). For example, the gate insulatingfilm 14 may be an insulating film of SiO₂, SiN_(X), SiON, Al₂O₃, Y₂O₃,Ta₂O₅, HfO₂, or the like or may be an insulating layer containing atleast two of these compounds.

The gate insulating film 14 is formed on the substrate 10 by a methodappropriately selected in consideration of the suitability to thematerial that is used to form the gate insulating film. Examples thereofinclude wet methods such as a printing method and a coating method;physical methods such as a vacuum deposition method, a sputteringmethod, and an ion plating method; and chemical methods such as CVD anda plasma CVD method. Then, patterning by a photolithography method andetching is performed to give a predetermined shape, as necessary.

Note that, the gate insulating film 14 should be thick enough to reducethe leak current and to improve the voltage resistance. However, whenthe gate insulating film 14 is too thick, a rise in drive voltageoccurs. Although the thickness of the gate insulating film 14 is set inconsideration of the material of the gate insulating film 14, thethickness of the gate insulating film 14 is preferably from 10 nm to 10μm, more preferably from 50 nm to 1000 nm, particularly preferably from100 nm to 400 nm.

Specifically, for example, the gate insulating film 14 may be formed bysubjecting an insulating film which is formed from silicon oxide (SiO₂),silicon nitride (SiN_(x)), or the like and which has a thickness of from100 to 400 nm to sputtering, CVD, or the like.

Active Layer (Semiconductor Layer)

After forming the gate insulating film 14, an IGZO film 16 including afirst layer 16A, a third layer 16C, and a second layer 16B is formed(see FIG. 3(D)).

The IGZO film 16 is formed, for example, by sputtering or the like, insuch a manner that the Zn ratio takes an absolute maximum value insidethe IGZO film; the absolute maximum value may simultaneously be a localmaximum value, and the same applies hereinafter.

For example, three layers may be formed in such a manner that a layerhaving a thickness of 10 nm and a compositional ratio of metal elementsIn, Ga, and Zn (i.e., In:Ga:ZN) of 1.0:1.0:1.0, a layer having athickness of 10 nm and a compositional ratio In:Ga:Zn of 1.0:1.0:2.0,and a layer having a thickness of 30 nm and a compositional ratioIn:Ga:Zn of 1.0:1.0:1.0, are formed in this order.

In other words, for example, there may be formed a first layer 16Ahaving an In:Ga:Zn ratio of 1.0:1.0:1.0 (thickness: 10 nm), a thirdlayer 16C having an In:Ga:Zn ratio of 1.0:1.0:2.0 (thickness: 10 nm),and a second layer 16B having an In:Ga:Zn ratio of 1.0:1.0:1.0(thickness: 30 nm) in this order.

The total thickness of IGZO film 16 is preferably from about 30 nm toabout 200 nm, and respective layers in the IGZO film are preferablyformed by a series of consecutive film-forming processes without beingexposed to the atmosphere.

The IGZO film may have a configuration in which the respective layersare not distinctly separated by interfaces. For example, the y value inthe ratio, In:Ga:Zn=1.0:1.0:y, may continuously change in the thicknessdirection, so that the y distribution in the IGZO film takes an absolutemaximum value inside the IGZO film; in this case, a region at which thevalue of y is at least 90% of the absolute maximum value of y ispreferably located in a region ranging from 1 nm to 30 nm from theinterface between the IGZO film 16 and the gate insulating film 14, asdescribed above.

When film formation in which the metal element ratio is changed isperformed by sputtering, the sputtering may be performed, for example,as follows. Specifically, co-sputtering may be performed using pluraltargets each selected from a Zn target, a Ga target or Zn target or asimple or complex oxide thereof, and the metal element ratio may bechanged by adjusting the current applied to one or some of the targets,a shielding plate for one or some of the targets, or the like.

For example, the IGZO film 16 (active layer) having the aboveconfiguration may be formed by co-sputtering using an InGaZnO₄ targetand a ZnO target in such a manner that a constant power of 200 W isapplied to the InGaZnO₄ target, and the power applied to the ZnO targetis changed within a range of from 0 to 60 W.

A distribution of y in the IGZO film 16 similar to the distribution dshown in FIG. 1 is obtained when, in the formation of the film, aconstant electric power is applied to a ZnO target during the formationof each of the first layer 16A, the third layer 16C, and the secondlayer 16B, and the electric power applied is swiftly changed to a nextpredetermined value when completing the formation of one layer to startformation of the next layer. The formation of the film may alternativelybe performed such that a constant electric power is applied to a ZnOtarget during the formation of each of the first layer 16A, the thirdlayer 16C, and the second layer 16B, and such that the electric powerapplied is gradually changed when completing the formation of one layerto start formation of the next layer, as a result of which the ydistribution becomes similar to the distribution e shown in FIG. 2. Inthe latter case, no distinct interfaces are formed between therespective layers.

Subsequently, the IGZO film 16 is patterned to form an active layer 18including a first layer 18A, a third layer 18C, and a second layer 18B(FIG. 4 (A)). Here, the active layer 18 is formed to have a pattern of,for example, an island shape, so that the active layer 18 has anoverlapping portion with the gate electrode 12 when viewed in the normaldirection of the substrate 10.

Patterning of the IGZO film 16 may be performed by a photolithographyand etching. Specifically, the IGZO film 16 provided on the gateinsulating film 14 is patterned by providing a resist at portions thatshould remain as the active layer 18 by photolithography, and thenetching the exposed portions of the IGZO film 16 with an acid solutionsuch as hydrochloric acid, nitric acid, dilute sulfuric acid, or a mixedliquid of phosphoric acid, nitric acid, and acetic acid (AL ETCHANT,trade name, manufactured by Kanto Chemical Co., Ltd.), as a result ofwhich the active layer 18 is formed. An aqueous solution includingphosphoric acid, nitric acid, and acetic acid is a preferable examplesince the use thereof ensures removal of the exposed portions of theIGZO film 16.

Source Electrode and Drain Electrode

Next, a metal film for forming a source electrode 20A and a drainelectrode 20B is formed on the active layer 18 and the gate insulatingfilm 14.

The metal film may be formed in the same manner as in the preparation ofthe metal film of the gate electrode 12.

The metal film is preferably a Mo film, an Al film, an Al—Mo film, or amultilayer film composed of a combination thereof, each of which isformed by, for example, sputtering.

In light of film forming property, capability of patterning by etchingor a lift-off, electric conductivity (reduction of electric resistance),and the like, it is preferred that the film thickness of the metal filmis from 10 nm to 1000 nm, and more preferably from 50 nm to 100 nm.

Next, the metal film is subjected to patterning by etching or lift-off,whereby a source electrode 20A and a drain electrode 20B, each of whichis in contact with the active layer 18, are formed (see FIG. 4 (B)).

The source electrode 20A and drain electrode 20B are each formed so asto have a portion overlapping the gate electrode 12 and the active layer18 when viewed in the normal direction of the substrate 10.

It is preferable that the patterning of the source electrode and drainelectrode is performed simultaneously with the patterning of wires (suchas data wires) that are connected to the source electrode and of wires(such as data wires) that are connected to the drain electrode.

Inter-Layer Insulating Film

After forming the source electrode 20A, the drain electrode 20B, and thewires, an inter-layer insulating film 22 is formed (FIG. 4 (C)).

Examples of materials that can be used to form the inter-layerinsulating film 22 include metal oxides such as MgO, SiO, SiO₂, Al₂O₃,GeO, NiO, CaO, BaO, Fe₂O₃, Y₂O₃, and TiO₂; metal nitrides such asSiN_(X) and SiN_(x)O_(y); metal fluorides such as MgF₂, LiF, AlF₃ andCaF₂; polyethylene; polypropylene; polymethyl methacrylate; polyimide;polyurea; polytetrafluoroethylene; polychlorotrifluoroethylene;polydichlorodifluoroethylene; copolymers of chlorotrifluoroethylene anddichlorodifluoroethylene; copolymers obtained by copolymerizing amonomer mixture containing tetrafluoroethylene and at least onecomonomer; fluorine-containing copolymers each having a cyclic structurein the copolymer main chain; water absorbing substances each having acoefficient of water absorption of 1% or higher; and moisture permeationpreventive substances each having a coefficient of water absorption of0.1% or lower.

The method of forming the inter-layer insulating film 22 is notparticularly limited. Examples of the method include a vacuum depositionmethod, a sputtering method, a reactive sputtering method, a molecularbeam epitaxy (MBE) method, a cluster ion beam method, an ion platingmethod, a plasma polymerization method (a radio frequency ion platingmethod), a plasma chemical vapor deposition (CVD) method, a laser CVDmethod, a thermal CVD method, a gas source CVD method, a coating method,a printing method, and a transferring method, and the method may beselected depending on the material.

The thickness of the inter-layer insulating film 22 is usually from 50nm to 10,000 nm, depending on the material or the like.

Specifically, for example, the inter-layer insulating film 22 may be aninsulating film of silicon oxide (SiO₂), silicon nitride (SiN_(x)), orthe like having a thickness of from 100 nm to 200 nm, which may beformed by, for example, sputtering or CVD.

Pixel Electrode

Subsequent to the formation of inter-layer insulating film 22, a contacthole 24 is formed to penetrate through the inter-layer insulating film22 by photolithography and etching (or lift-off), and a pixel electrode26 and the like are then formed (see FIG. 4(D)).

For example, after a film of indium tin oxide (ITO) is formed bysputtering, the film may be patterned by photolithography and etching(or lift-off), whereby a patterned pixel electrode 26, which connects tothe drain electrode 20B through the contact hole 24, is obtained.

Other than the ITO used in the above description, the pixel electrode 26may alternatively be formed from Al, Al—Nd, or the like.

The TFT described above has a Zn-rich region (region in which the Znmolar ratio is high) in a part of the active layer 18 (the third layer18C); therefore, characteristics shift is reduced while a high on-statecurrent is achieved.

Since the characteristics shift is reduced, the gate bias required toget the TFT to be in the off-state can be reduced, and electricalconsumption for driving the TFT can be reduced.

The TFT described above is a bottom-gate top-contact TFT amongbottom-gate TFTs. However, a bottom-gate bottom-contact TFT can beobtained by changing the order of formation of the active layer 18, thesource electrode 20A, and the drain electrode 20B (i.e., changing thelayer configuration) in the TFT.

Some embodiments of the invention are described in the above; however,the invention is not limited to these embodiments.

For example, at least one of the inter-layer insulating film 22 or thepixel electrode 26 may be omitted.

Furthermore, the invention is not limited to a bottom-gate TFT, and maybe applied to a top-gate TFT having a configuration as shown in FIG. 5,for example. When the invention is applied to a top-gate TFT having aconfiguration as shown in FIG. 5, an IGZO film may be formed on asubstrate 10, and subjected to patterning to form an active layer 18,and a source electrode 20A and a drain electrode 20B may be formedthereon, followed by forming a gate insulating film 14 and a gateelectrode 12 in this order.

The IGZO film preferably includes a first layer, a second layer, and athird layer (which respectively correspond to the first layer 18A, thesecond layer 18B, and the third layer 18C in the active layer 18 shownin FIG. 5), similar to the IGZO film in the bottom-gate TFT.

It is preferable that the center, in the thickness direction, of aregion at which the absolute maximum y value over the y distribution ispositioned at a side closer to the gate insulating film with respect tothe center of the IGZO film (active layer 18) in the thicknessdirection. In a specific example of such an embodiment, a first layer18A in which In:Ga:Zn ratio is 1.0:1.0:1.0 (thickness: 30 nm), a thirdlayer 18C in which In:Ga:Zn ratio is 1.0:1.0:2.0 (thickness: 10 nm), anda second layer 18B in which In:Ga:Zn ratio is 1.0:1.0:1.0 (thickness: 10nm) are provided in this order on a substrate 10.

As described above, the TFT described above by referring to FIG. 5 is atop-gate top-contact TFT among top-gate TFTs. However the TFT of theinvention can be made to be a top-gate bottom-contact TFT by changingthe order of formation of the active layer 18, the source electrode 20A,and the drain electrode 20B (i.e., changing the layer configuration).

The application of the thin film transistor of the invention is notparticularly limited. The thin film transistor of the invention ispreferably used, for example, for a driving device of electroopticapparatuses (such as liquid crystal display devices, organicelectroluminescence (EL) display devices, or inorganic EL displaydevices).

Furthermore, the electronic device of the invention is preferably usedfor a driving device (driving circuit) of various electronic devicessuch as devices which can be prepared by a low-temperature process usinga resin substrate (such as flexible displays), various sensors such asX-ray sensors, and micro electro mechanical systems (MEMS).

Electrooptic Apparatus and Sensor

The electrooptic apparatus of the invention and the sensor of theinvention each include the above-described thin film transistor of theinvention.

Examples of the electrooptic apparatus include display apparatuses suchas liquid crystal display apparatuses, organic electroluminescence (EL)display apparatuses, and inorganic EL display apparatuses.

Examples of the sensor include image sensors such as charge coupleddevices (CCDs) and complementary metal oxide semiconductors (CMOSs) andX-ray sensors.

Since the electrooptic apparatus or sensor of the invention includes thethin film transistor of the invention, which exhibits a high on-statecurrent and reduced characteristics shift, the electrooptic apparatus orsensor exhibits excellent properties with low electrical consumption.

Here, the “properties” refer to the display properties when used inconnection with an electrooptic apparatus, and refer to the sensitivityproperties when used in connection with a sensor.

FIG. 6 is a conceptual diagram illustrating a liquid crystal display200, which is an example of the display of the invention.

As shown in FIG. 6, the liquid crystal display 200 is equipped withplural gate wires 210 which are parallel to each other and plural datawires 220 which are parallel to each other. The data wires 220 and thegate wires 210 are placed in such a manner that the data wires 220 areintersected with the gate wires 210. Here, the gate wires 210 areelectrically insulated from the data wires 220. A thin film transistor(TFT) 230, which is a thin film transistor of the invention, is disposedin a portion at or around an intersection of a gate wire 210 and a datawire 220.

A gate electrode of the thin film transistor 230 is connected to thegate wire 210, and a source electrode of the thin film transistor 230 isconnected to the data wire 220. Further, a drain electrode of the thinfilm transistor 230 is connected to a pixel electrode. A liquid crystal250 is held between the pixel electrode and an opposing electrode (notshown). Moreover, the pixel electrode and an earthed opposing electrodeform a condenser 240.

Since the TFT 230 exerts a high carrier mobility and a high on/offratio, high-quality properties including high fineness, high-speedresponse, high contrast and the like are imparted to the liquid crystaldisplay device 200. When the IGZO used in the active layer is amorphous,variations of device properties can be suppressed, whereby unevennesscan be suppressed and excellent display quality can be achieved even ina large-size display. In addition, since the characteristics shift isreduced, the gate bias can be reduced, and electrical consumption of adisplay device can be reduced.

According to the invention, a semiconductor layer can be prepared usingan IGZO film which is capable of film formation at low temperatures (forexample, at 200° C. or less) to produce the thin film transistor 230.Therefore, a resin substrate (plastic substrate) can be used as thesubstrate.

According to the invention, a flexible liquid crystal display devicehaving an excellent display quality, and a flexible organic EL devicehaving excellent display quality can be provided.

FIG. 7 is a conceptual sectional view illustrating an X-ray sensor 300,which is an example of the sensor of the invention. More specifically,FIG. 7 is a magnified conceptual sectional view showing a part of anX-ray sensor array.

As shown in FIG. 7, the X-ray sensor 300 includes a substrate 310, a TFT320 and a capacitor 330 which are disposed on a substrate 310, anelectric charge-collecting electrode 350 which is disposed on thecapacitor 330, an X-ray conversion layer 360, and an upper layerelectrode 370.

In FIG. 7, the TFT 320 is a top-gate TFT similar to the TFT shown inFIG. 5; however, the TFT in the sensor of the invention is not limitedto a top-gate TFT and may be a bottom-gate TFT.

A passivation film 340 is provided on the TFT 320.

The capacitor 330 has a configuration in which an insulating film 314 isinterposed between a capacitor-lower electrode 380 and a capacitor-upperelectrode 390. The material of the capacitor-lower electrode 380 is thesame as the material of a source electrode and drain electrode of theTFT 320. The capacitor-lower electrode 380 is formed by patterningsimultaneously with patterning of the source electrode and drainelectrode of the TFT 320. The capacitor-upper electrode 390 is connectedto either one of the source electrode or drain electrode of the TFT 320through a contact hole that is provided to penetrate through theinsulating film 314.

The electric charge-collecting electrode 350 is provided on thecapacitor-upper electrode 390 in the capacitor 330, and is in contactwith the capacitor-upper electrode 390.

The X-ray conversion layer 360 is a layer including amorphous selenium,and is provided over the TFT 320 and the capacitor 330.

The upper layer electrode 370 is provided on the X-ray conversion layer360, and is in contact with the X-ray conversion layer 360.

In the X-ray sensor 300 having the above configuration, X-rays areirradiated from the upper part in FIG. 7 (from the upper layer electrode370 side), and electron-hole pairs are generated in the X-ray conversionlayer 360. When a high electrical field is applied to the X-rayconversion layer 360 by the upper electrode 370, the generated chargesare accumulated in the capacitor 330, and read out by sequentiallyscanning the TFT 320.

In the X-ray sensor 300, the highly reliable TFT 320 is provided whichexhibits a high on-state current and a reduced characteristics shift;therefore, the X-ray sensor 300 has a high S/N ratio and excellentsensitivity, and high dynamic range images can be obtained. Furthermore,when the IGZO in the active layer of the TFT 320 is amorphous, highlyuniform images can be obtained.

EXAMPLES

In the following, the present invention is further described in detailwith reference to examples. However, the examples should not beconstrued as limiting the present invention. Unless otherwise noted,“part(s)” and “%” are on the mass basis.

Example 1 Production of Bottom-Gate TFT

A bottom-gate TFT was prepared in accordance with the above-describedexample of a method of producing a thin film transistor (FIGS. 3 and 4).

Here, an alkali-free glass substrate (trade name: No. 1737, manufacturedby Corning Inc.) was used as a substrate 10.

First, an Al—Nd film having a thickness of 100 nm was formed bysputtering, and then was subjected to patterning by photolithography andwet etching using a commercially-available Al etching liquid, therebyforming a gate electrode 12.

Then, a gate insulating film 14 having a thickness of 150 nm was formedby sputtering SiO₂.

Subsequently, a layer having an In:Ga:Zn ratio of 1.0:1.0:1.0(thickness: 10 nm), a layer having an In:Ga:Zn ratio of 1.0:1.0:2.0(thickness: 10 nm), and a layer having an In:Ga:Zn ratio of 1.0:1.0:1.0(thickness: 30 nm) were formed on the gate insulating film 14 in thisorder by a series of consecutive film-forming processes without beingexposed to the atmosphere, thereby forming an IGZO film 16.

Hereinafter, the layer configuration of the IGZO film 16 (active layer18) of Example 1 may be represented by “In:Ga:Zn=1:1: (1→2→1)” or“1→2→1”.

The layers of the IGZO film were formed by co-sputtering using anInGaZnO₄ target, a Ga₂O₃ target, and a ZnO target.

The thicknesses of the respective layers were adjusted by controllingthe duration of the film-forming processes.

Details of the sputtering conditions for forming the IGZO film 16 weredescribed in the following.

Sputtering conditions for forming IGZO Film (In:Ga:Zn=1.0:1.0:1.0)

Final vacuum degree (when gas is not introduced): 6×10⁻⁶ PaFilm-forming pressure (when gas is introduced): 4.07×10⁻¹ PaFilm-forming temperature: room temperature (substrate temperature: from23° C. to 25° C.)Flow rate of Ar: 100 sccmFlow rate of O₂: 0.9 sccmPower applied to IGZO target: RF 200 WPower applied to Ga₂O₃ target: RF 63 WPower applied to ZnO target: DC 4.3 W

Sputtering conditions for forming IGZO film (In:Ga:Zn=1.0:1.0:2.0)

Final vacuum degree (when gas is not introduced): 6×10⁻⁶ PaFilm-forming pressure (when gas is introduced): 4.07×10⁻¹ PaFilm-forming temperature: room temperature (substrate temperature: from23° C. to 25° C.)Flow rate of Ar: 100 sccmFlow rate of O₂: 0.9 sccmPower applied to IGZO target: RF 200 WPower applied to Ga₂O₃ target: RF 63 WPower applied to ZnO target: DC 19.0 W

The y distribution in the thickness direction of the resultant IGZO film16, when the molar ratio of In:Ga:Zn is represented by the followingexpression In:Ga:Zn=(2.0−x):x:y (provided that, 0.0<x<2.0, and 0.0<y),was determined in a such a manner that a sample was subjected to FIBtreatment and evaluated by cross-sectional TEM-EDX (a TEM availableunder the trade name of HD-2700 from Hitachi, and an EDX available fromEDAX under the trade name of GENESIS). The evaluation conditions weresuch that: a beam diameter was 0.4 nm, measurement time per one pointwas 1 second, and the number of measurement points was 150.

The obtained y distribution confirmed the presence a region in which thevalue of y is larger than that at a surface of the IGZO film at a sidecloser to the substrate and that at a surface of the IGZO film at a sidefarther from the substrate.

The obtained y distribution was similar to the distribution d shown inFIG. 1.

The thickness t_(max) of a region at which the value of y is at least90% of the absolute maximum y value within the IGZO film was 10 nm, andwas less than one-third of the entire thickness of the IGZO film, whichwas 50 nm.

Furthermore, the region at which the y value is at least 90% of theabsolute maximum y value over the y distribution was present in a regionranging from 10 nm to 20 nm from the surface of the gate-insulating-filmside of the IGZO film in the thickness direction thereof, and includedin the region ranging from 1 nm to 30 nm from the surface of thegate-insulating-film side of the IGZO film.

The center, in the thickness direction, of the region at which the yvalue was at least 90% of the absolute maximum y value was positioned ata side closer to the gate insulating film with respect to the center ofthe oxide semiconductor film in the thickness direction.

The IGZO film 16 was subjected to X-ray diffraction. As a result, nodistinct peak indicating a crystalline structure was found, and it wasconfirmed that the IGZO film 16 was amorphous.

A TFT can be prepared by a similar process in which the power applied tothe ZnO target during the sputtering for the formation of the IGZO film16 is continuously changed from 4.3 W to 19.0 W when starting theformation of the center layer and is continuously changed from 19.0 W to4.3 W when finishing the formation of the center layer, instead offorming three distinct layers. When a TFT produced by such a process wassubjected to analysis of y distribution in the same manner as above, itwas found that the TFT had a y distribution similar to the distributioncurve “e” shown in FIG. 2.

The IGZO film 16 was subjected to patterning by photolithography and wetetching using dilute sulfuric acid, thereby forming the active layer 18.

An Al—Nd film having a thickness of 100 nm was formed by sputtering, andsubjected to patterning by lift-off, thereby forming a source electrode20A and a drain electrode 20B.

A SiO₂ film having a thickness of 200 nm was formed by sputtering,thereby forming an inter-layer insulating film 22.

A contact hole 24 was formed by photolithography and dry etching.

An ITO film having a thickness of 200 nm was formed by sputtering, andsubjected to patterning by lift-off, thereby forming a pixel electrode26.

In this way, a bottom-gate TFT having a channel length of 10 μm and achannel width of 10 μm was obtained.

Measurement of Transistor Properties (Vd-Ig Characteristics)

The thus-obtained TFT was subjected to measurement of transistorproperties (Vg-Id characteristics) and carrier mobility (μ) using asemiconductor parameter analyzer 4156C (trade name, manufactured byAgilent Technologies).

The Vg-Id characteristics were measured by changing the gate voltage(Vg) within a range of from −5 V to +10 V with a fixed drain voltage(Vd) of 5 V, and measuring the drain current (Id) at each gate voltage(Vg).

Comparative Example 1

A TFT was prepared in the same manner as in Example 1 except that theIGZO film 16 was composed of only the layer having an In:Ga:Zn ratio of1.0:1.0:1.0 and having a thickness of 50 nm, and the same evaluation asin Example 1 was performed.

In the following, the layer configuration of the IGZO film 16 (activelayer 18) of Comparative Example 1 may be referred to as“In:Ga:Zn=1:1:1” or “1→1→1”.

Comparative Example 2

A TFT was prepared in the same manner as in Example 1 except that theIGZO film 16 was composed of only the layer having an In:Ga:Zn ratio of1.0:1.0:2.0 and having a thickness of 50 nm, and the same evaluation asin Example 1 was performed.

In the following, the layer configuration of the IGZO film 16 (activelayer 18) of Comparative Example 2 may be referred to as“In:Ga:Zn=1:1:2” or “2→2→2→”.

The results of measurement of Vg-Id characteristics of Example 1 andComparative Examples 1 and 2 are shown in FIGS. 8 and 9.

FIG. 8 is a graph in which the vertical axis represents Id on alogarithmic scale, and FIG. 9 is a graph in which the vertical axisrepresents Id on a linear scale.

As shown in FIG. 8, when Example 1 (In:Ga:Zn=1:1: (1→2→1)) is comparedto Comparative Example 1 (In:Ga:Zn=1:1:1), almost no shift in Vg-Idcharacteristics is observed in Example 1. For example, when the value atId of 1.0×10⁻⁹ A of Example 1 is compared to that of Comparative Example1, the shift of Vg from Comparative Example 1 observed in Example 1 isabout 0.3 V towards the negative Vg side, which is a slight shift.

Furthermore, provided that Id at Vg of 10 V is regarded as the on-statecurrent, the on-state current in Comparative Example 1 was 2.0×10⁻⁶ A,while the on-state current in Example 1 was 6.0×10⁻⁶ A.

In addition, the carrier mobility μ in Comparative Example 1 was 7.9(cm²/Vs) while the carrier mobility μ in Example 1 was 24.7 (cm²/Vs).

Accordingly, the TFT of Example 1 showed significantly higher on-statecurrent and significantly improved carrier mobility as compared to theTFT of Comparative Example 1.

On the other hand, Comparative Example 2 (In:Ga:Zn=1:1:2) showed a highon-state current, but significant Vg-Id characteristics shift wasobserved as compared with Example 1 and Comparative Example 1.

For example, when the value at Id of 1.0×10⁻⁹ A of Comparative Example 2is compared to that of Example 1 and that of Comparative Example 1, theshift of Vg from Comparative Example 1 observed in Comparative Example 2is at least 1.5 V towards the negative Vg side, and the shift of Vg fromExample 1 observed in Comparative Example 2 is at least 1.3 V towardsthe negative Vg side, which is a significant shift.

Example 2

A TFT was prepared in the same manner as in Example 1 except that thelayer having an In:Ga:Zn ratio of 1.0:1.0:2.0 (thickness: 10 nm) waschanged to a layer having an In:Ga:Zn ratio of 1.0:1.0:3.0 (thickness:10 nm) by controlling the film formation conditions, and the measurementof Vg-Id characteristics and carrier mobility and the evaluation wereperformed in the same manner as in Example 1.

In the following, the layer configuration of the IGZO film 16 (activelayer 18) of Example 2 may be referred to as “In:Ga:Zn=1:1: (1→3→1)” or“1→3→1”.

Example 3

A TFT was prepared in the same manner as in Example 1 except that thelayer having an In:Ga:Zn ratio of 1.0:1.0:2.0 (thickness: 10 nm) waschanged to a layer having an In:Ga:Zn ratio of 1.0:1.0:5.0 (thickness:10 nm) by controlling the film formation conditions, and the measurementof Vg-Id characteristics and carrier mobility, and the evaluation wereperformed in the same manner as in Example 1.

In the following, the layer configuration of the IGZO film 16 (activelayer 18) of Example 3 may be referred to as “In:Ga:Zn=1:1: (1→5→1)” or“1 →5→1”.

FIG. 10 shows a comparison in carrier mobility of Examples 1 to 3 andComparative Example 1, and FIG. 11 shows a comparison in on/off ratio(on-state current (Ion)/off-state current (Ioff)) of Examples 1 to 3 andComparative Example 1.

The on-state current was a drain current (A) at Vg of 10 V and Vd of 5V, and the off-state current was a drain current (A) at Vg of −5V and Vdof 5 V.

Each of the horizontal axes of FIGS. 10 and 11 indicates the y value inthe center layer (the third layer 18C shown in FIG. 4(D)). In FIGS. 10and 11, Comparative Example 1 is plotted at y=1.0, Example 1 is plottedat y=2.0, Example 2 is plotted at y=3.0, and Example 3 is plotted aty=5.0.

Herein (for example, in Table 1 and FIGS. 8, 9 and 11), the symbol “E”when used in the values of Id and on/off ratio indicates that thenumeral at the right of “E” is an exponent to the base 10, and that thevalue at the left of “E” is multiplied by the value represented by “E”and “power index”. For example, “1.8E+07” represents “1.8×10⁷”, and“1.5E−09” represents “1.5×10⁻⁹”.

The results shown in FIGS. 10 and 11 are briefly summarized in Table 1.Furthermore, Table 1 shows the drain current (“Id (A) (Vg=0 v)”) at Vgof 0 V.

TABLE 1 Layer configuration Carrier On/off of active layer: mobility μratio Id (A) y value (cm²/Vs) (Ion/Ioff) (Vg = 0 V) Example 1 1→2→1 24.71.8E+07 1.8E−10 Example 2 1→3→1 16.6 6.0E+06 1.5E−09 Example 3 1→5→114.8 2.4E+06 1.3E−08 Comparative 1→1→1 7.9 2.1E+06 4.4E−11 Example 1Comparative 2→2→2 23.4 1.5E+07 5.3E−08 Example 2

As shown in FIG. 10 and Table 1, the carrier mobility μ in Examples 1 to3 (especially, Example 1) was higher than that in Comparative Example 1.

As shown in FIG. 11 and Table 1, the on/off ratio in Examples 1 to 3(especially, Example 1) was higher than that in Comparative Example 1.

Furthermore, as shown in Table 1, the Id at Vg of 0 V in Examples 1 to 3(especially, Example 1) was lower than that in Comparative Example 2,and characteristics shift in Examples 1 to 3 (especially, Example 1) wasreduced as compared to Comparative Example 2.

As described above, when an IGZO layer as an active layer of a TFT isformed so as to have a region at which the y value is larger than thatat the film surface at a side closer to a substrate and that at the filmsurface at a side farther from the substrate, characteristics shift canbe reduced while a high on-state current (high carrier mobility) can beattained, whereby gate bias applied in order to turn off the TFT can bereduced. Accordingly, a normally-off TFT can easily be obtained whileattaining a sufficient on-state current. Furthermore, since the gatebias is reduced, electrical consumption required to drive the TFT can bereduced.

Moreover, by using, as a component, the TFT (or substrate with a TFT)prepared as described above, an electrooptic apparatus or sensor withlow electrical consumption and excellent properties can be produced.

According to the invention, a thin film transistor which has a highon-state current and in which characteristics shift is reduced, and amethod of producing the same are provided.

According to the invention, an electrooptic apparatus with lowelectrical consumption and high display quality is provided.

According to the invention, a sensor with low electrical consumption andhigh sensitivity is provided.

Embodiments of the present invention include, but are not limited to,the following.

<1> A thin film transistor comprising:

a substrate; and, on the substrate,

an oxide semiconductor film which serves as an active layer andcomprises In, Ga, and Zn, a gate electrode, a gate insulating film, asource electrode, and a drain electrode,

wherein, when a molar ratio of In, Ga, and Zn in the oxide semiconductorfilm is expressed as In:Ga:Zn=(2.0−x):x:y, wherein 0.0<x<2.0 and 0.0<y,the distribution of y in the thickness direction of the oxidesemiconductor film is such that the oxide semiconductor film has aregion in which a value of y is larger than that at a surface of theoxide semiconductor film at a side closer to the substrate and largerthan that at a surface of the oxide semiconductor film at a side fartherfrom the substrate.

<2> The thin film transistor according to <1>, wherein an absolutemaximum value of y over an entire thickness of the oxide semiconductorfilm is 1.8 or more.<3> The thin film transistor according to <1> or <2>, wherein theabsolute maximum value of y over the entire thickness of the oxidesemiconductor film is 5.0 or less.<4> The thin film transistor according to any one of <1> to <3>, whereina thickness of a region in which the value of y is at least 90% of theabsolute maximum value thereof over the entire thickness of the oxidesemiconductor film is less than one-third of the entire thickness of theoxide semiconductor film.<5> The thin film transistor according to any one of <1> to <4>, whereina center of the region in which the value of y is at least 90% of theabsolute maximum value thereof over the entire thickness of the oxidesemiconductor film is located at a position at a side closer to the gateinsulating film than the center of the oxide semiconductor layer in thethickness direction thereof.<6> The thin film transistor according to any one of <1> to <5>, whereinthe region in which the value of y is at least 90% of the absolutemaximum value thereof over the entire thickness of the oxidesemiconductor film is included in a region ranging from 1 nm to 30 nmfrom the surface of the oxide semiconductor film at a side closer to thegate insulating film in a thickness direction of the oxide semiconductorfilm.<7> The thin film transistor according to any one of <1> to <6>, whereinat least a part of the oxide semiconductor film which includes theregion in which the value of y is at least 90% of the absolute maximumvalue thereof over the entire thickness of the oxide semiconductor filmis formed by a series of consecutive film-forming processes during whichthe semiconductor film is not exposed to the atmosphere.<8> The thin film transistor according to any one of <1> to <7>, whereinat least a part of the oxide semiconductor film which includes theregion in which the value of y is at least 90% of the absolute maximumvalue thereof over the entire thickness of the oxide semiconductor filmis amorphous.<9> The thin film transistor according to any one of <1> to <8>, whereinthe oxide semiconductor film comprises:

a first region which includes the surface of the oxide semiconductorfilm at a side closer to the substrate and in which the value of y isfrom 0.8 to 1.2;

a second region which includes the surface of the oxide semiconductorfilm at a side farther from the substrate and in which the value of y isfrom 0.8 to 1.2; and

a third region which includes a region in which y takes the absolutemaximum value over the entire thickness of the oxide semiconductor filmand in which the value of y is 1.8 or more.

<10> The thin film transistor according to <9>, wherein at least one ofa change in the value of y from the first region to the third region anda change in the value of y from the third region to the second region iscontinuous.<11> The thin film transistor according to any one of <1> to <10>,wherein the thin film transistor is a bottom-gate thin film transistor.<12> A method of producing the thin film transistor according to any oneof <1> to <11>, the method comprising:

forming at least a part of the oxide semiconductor film which includesthe region in which the value of y is at least 90% of the absolutemaximum value thereof over the entire thickness of the oxidesemiconductor film by a series of consecutive film-forming processesduring which the oxide semiconductor film is not exposed to theatmosphere.

<13> An electrooptic apparatus comprising the thin film transistoraccording to any one of <1> to <11>.<14> A sensor comprising the thin film transistor according to any oneof <1> to <11>.

All publications, patent applications, and technical standards mentionedin this specification are herein incorporated by reference to the sameextent as if each individual publication, patent application, ortechnical standard was specifically and individually indicated to beincorporated by reference.

1. A thin film transistor comprising: a substrate; and, on thesubstrate, an oxide semiconductor film which serves as an active layerand comprises In, Ga, and Zn, a gate electrode, a gate insulating film,a source electrode, and a drain electrode, wherein, when a molar ratioof In, Ga, and Zn in the oxide semiconductor film is expressed asIn:Ga:Zn=(2.0−x):x:y, wherein 0.0<x<2.0 and 0.0<y, the distribution of yin the thickness direction of the oxide semiconductor film is such thatthe oxide semiconductor film has a region in which a value of y islarger than that at a surface of the oxide semiconductor film at a sidecloser to the substrate and larger than that at a surface of the oxidesemiconductor film at a side farther from the substrate.
 2. The thinfilm transistor according to claim 1, wherein an absolute maximum valueof y over an entire thickness of the oxide semiconductor film is 1.8 ormore.
 3. The thin film transistor according to claim 1, wherein anabsolute maximum value of y over an entire thickness of the oxidesemiconductor film is 5.0 or less.
 4. The thin film transistor accordingto claim 1, wherein a thickness of a region in which the value of y isat least 90% of an absolute maximum value thereof over an entirethickness of the oxide semiconductor film is less than one-third of theentire thickness of the oxide semiconductor film.
 5. The thin filmtransistor according to claim 1, wherein a center of a region in whichthe value of y is at least 90% of an absolute maximum value thereof overan entire thickness of the oxide semiconductor film is positioned at aside closer to the gate insulating film than the center of the oxidesemiconductor layer in a thickness direction thereof.
 6. The thin filmtransistor according to claim 1, wherein a region in which the value ofy is at least 90% of an absolute maximum value thereof over an entirethickness of the oxide semiconductor film is included in a regionranging from 1 nm to 30 nm from a surface of the oxide semiconductorfilm at a side closer to the gate insulating film in a thicknessdirection of the oxide semiconductor film.
 7. The thin film transistoraccording to claim 1, wherein at least a part of the oxide semiconductorfilm which includes a region in which the value of y is at least 90% ofan absolute maximum value thereof over an entire thickness of the oxidesemiconductor film is formed by a series of consecutive film-formingprocesses during which the semiconductor film is not exposed to theatmosphere.
 8. The thin film transistor according to claim 1, wherein atleast a part of the oxide semiconductor film which includes a region inwhich the value of y is at least 90% of an absolute maximum valuethereof over an entire thickness of the oxide semiconductor film isamorphous.
 9. The thin film transistor according to claim 1, wherein theoxide semiconductor film comprises: a first region which includes thesurface of the oxide semiconductor film at a side closer to thesubstrate and in which the value of y is from 0.8 to 1.2; a secondregion which includes the surface of the oxide semiconductor film at aside farther from the substrate and in which the value of y is from 0.8to 1.2; and a third region which includes a region in which y takes anabsolute maximum value over an entire thickness of the oxidesemiconductor film and in which the value of y is 1.8 or more.
 10. Thethin film transistor according to claim 9, wherein at least one of achange in the value of y from the first region to the third region and achange in the value of y from the third region to the second region iscontinuous.
 11. The thin film transistor according to claim 1, whereinthe thin film transistor is a bottom-gate thin film transistor.
 12. Amethod of producing the thin film transistor of claim 1, the methodcomprising: forming at least a part of the oxide semiconductor filmwhich includes a region in which the value of y is at least 90% of anabsolute maximum value thereof over an entire thickness of the oxidesemiconductor film by a series of consecutive film-forming processesduring which the oxide semiconductor film is not exposed to theatmosphere.
 13. An electrooptic apparatus comprising the thin filmtransistor of claim
 1. 14. A sensor comprising the thin film transistorof claim 1.